Everlast PowerARC 210ST, Operator'S Manual

Page 1: ...Setup and General Use Guide Rev 2 1 00 181115 Nov 18 DC Stick DC Pulse TIG Inverter Welder CC GTAW SMAW IGBT 1 PHASE DC everlastwelders com 1 877 755 9353 380 Swift Ave South San Francisco CA 94080 USA Specifications and accessories subject to change without notice 120V 240V ...

Page 2: ... tities appearance and specifications of the product in this manual are subject to change without notice or up date of this manual This manual is intended to be a general guide and not intended to be exhaustive in its content regarding safety welding or the operation maintenance of this unit Everlast Power Equipment INC does not guarantee the accuracy completeness authority or authenticity of the ...

Page 3: ...ance technical support available through the main company headquarters available in your country For best service call the appropriate support line and follow up with an email particularly if off hours or you cannot reach a live person In the event you do not reach a live person particularly during heavy call volume times holidays and off hours leave a message and your call will normally be return...

Page 4: ...r 1 877 755 WELD 9353 Sales Ext 201 9am 5pm PST M F Tech Support Ext 207 9am 5pm EST M F Welding Support Ext 204 9am 5pm EST M F FAX 1 650 588 8817 Everlast Canada Everlast consumer satisfaction email sales everlastwelders ca Everlast Website everlastwelders ca Everlast Technical Support sales everlastwelders ca Telephone 905 630 8246 9am 4 30pm EST M F FAX 1 905 639 2817 Everlast Australia Sydney...

Page 5: ...erformance out of your unit Do not operate the unit until you have read this manual and are thoroughly familiar with the safe operation of the unit If you feel you need more information about operating your unit please contact Everlast Support The warranty does not cover improper use maintenance or consumables Do not attempt to alter or defeat any piece or part of your unit particularly any safety...

Page 6: ... protective equipment If no protection is availa ble exclude them from the work area Even brief exposure to the rays from the welding arc can damage unprotected eyes Always wear hearing protection because welding and cutting can be extremely noisy Ear protec tion is necessary to prevent hearing loss Even prolonged low levels of noise has been known to cre ate long term hearing damage Hearing prote...

Page 7: ...ation Stop immediately and relocate work if necessary until adequate ventilation is obtained Stop work completely and seek medical help if irritation and discomfort persists WARNING Do not weld on galvanized steel stainless steel beryllium titanium copper cadmium lead or zinc without proper respiratory equipment and or ventilation WARNING This product when used for welding or cutting produces fume...

Page 8: ...htest traces of smoke or embers If welding or cutting outside make sure you are in a cleared off area free from dry tender and debris that might start a forest or grass fire Do not weld on tanks drums or barrels that are closed pressurized or anything that held flamma ble liquid or material Keep cylinders turned off when not in use Turn off all cylinders and remove regulators when the machine is e...

Page 9: ...ating ball type regulator Foot Pedal optional Current Output Type DC Cellulose Electrode Capable 6010 6011 Yes with special selection for E6010 operation DINSE Connector Type 35 50mm DINSE 35 STYLE Hot Start Adjustable Intensity 0 100 and Duration 0 2 Seconds Arc Force Control Adjustable 0 100 Voltage Reduction Device VRD for Stick Selectable On or Off when on V 24V Anti Stick Function Selectable ...

Page 10: ...re the chances of electrocution may be present TIG Features Additionally the unit has been improved in TIG function and features The user now has 2 choices for starting the arc which can be cho sen to match the type of operation that is re quired in different circumstances The low con tamination Live lift function provides a continu ously live arc and allows the arc to be struck without the use of...

Page 11: ...elmet If you take a glance keep your welding helmet hood in the down position The welder also features an adjustable post flow which stops gas flow once the arc is terminated according to the time set on the panel with the control The post flow tim er provides proper shielding of the weld pool from the atmosphere as it cools and also helps to cool the torch head A good rule of thumb to use is to s...

Page 12: ...is the final stage of the weld cycle This allows time for extra filler metal to be added to fill and round off the top of the crater the unfilled bot tom part of the weld puddle This feature helps control crater cracks which cause premature weld failures Setting at down slope time is an important part of using correct weld technique While no exact setting for down slope time is recommended per amp...

Page 13: ...VRD excels at what it does Howevr it does not eliminate all risk of electrocution from the user coming into contact with power input cables or internal parts of the machine Common sense and adherence to safety practices should be employed at all times when the VRD is required to be used Note that while reducing shock risk the VRD can reduce arc starting efficiency and can cause the arc to be more ...

Page 14: ...t and vermin nests Once a month or as needed clean the machine thoroughly inside and out with compressed air To do this remove the rear plastic cover first check for screws on the bottom Then remove the screws on the metal cover Pull the cover off by slightly spreading flexing the bottom flaps of the metal cover with your fingers Pull up and to the rear to remove the cover Do not attempt to remove...

Page 15: ... being adjusted Values indicated Hertz Hz Seconds S Per cent Amps A Error Warning ON Status 10 The Positive Terminal DINSE 25 type is used to connect the Stick electrode holder in Stick mode In TIG mode the work clamp is connected here 11 The Shielding Gas Quick Connect Coupling is used to con nect the gas line from the DINSE 25 type TIG torch con nector When the gas line is fully inserted into co...

Page 16: ...OR INJURIES RESULTING FROM IMPROPER WIRING Fe Cu Even though the unit is grounded by the main ground wire to the chassis an additional bonded ground may be necessary in some locations to comply with code Consult a locally licensed electrician concerning the any requirement of this connection and its proper use and application in your region This connection may be used to help reduce and drain HF i...

Page 17: ...TART INTENSITY HOT START TIME STICK ARC FORCE TIG PREFLOW TIG DOWNSLOPE 8 8 8 HF START IMPORTANT READ OPERATOR S MANUAL BEFORE USE GAS OUTLET PowerARC 210STL STICK WELDING CONFIGURATION TORCH WORK WORK CLAMP TORCH ELECTRODE HOLDER General Setup and Operation Section 2 POLARITY STICK MODE TORCH POSITIVE WORK NEGATIVE ...

Page 18: ...t Pedal POLARITY TIG MODE TORCH POSITIVE WORK POSITIVE WORK WORK CLAMP General Setup and Operation Section 2 TORCH TIG TORCH WITH SWITCH FROM SWITCH NOTE FOOT PEDAL IS OPTIONAL Purchase a long life NOVA foot pedal or torch mounted NOVA Slider Amp Control direct from Everlast if needed to adjust amps while welding Additionally optional TIG torches including high quality NOVA torches are also availa...

Page 19: ...ed the machine side fitting may strip the hole and begin to turn in the housing and begin to twist the solenoid which the machine mounted fitting is screwed directly into Do not overtighten any fitting Only use an adjustable wrench if no exact fit wrench is available Usually 1 8 1 4 turn after the fitting first begins to make full contact with the female fitting seat is sufficient for establishing...

Page 20: ...ut no neutral Care should be exercised when wiring a new plug and making any modifications to existing wiring A licensed electrician that is familiar with local wiring codes should be consulted before using adding to or making any changes to existing circuits The information given on the graphic located on the welder supplies the necessary information for breaker and wire sizing This information i...

Page 21: ...maintain the arc Cellulose electrodes may not have the same arc force behavior as other welding electrodes but each brand and size will weld a little differently Typically rods such as the E6011 will require a setting over 50 for best results The arc force control setting will vary from person to person as well with different rod angles positions and arc lengths all factoring into the arc force co...

Page 22: ...ce running slowly without filler metal first Keep the torch head inclined away from the direction of trav el so the Tungsten stays just above the puddle pointed toward the front of the puddle Move slow ly and methodically gauging your forward move ment to make sure it is steady and paced Imagine a thick coin is able to be placed between the tip of the Tungsten and the weld puddle As your skill pro...

Page 23: ...an be slid with gentle pressure into the puddle as needed to fill the weld This is known as the Lay Wire tech nique Another method of welding has more to do with torch manipulation than it does filler addition is called walking the cup The cup is rested on the metal while the torch head is oscillated in a figure 8 pattern This will require a forehand grip typical ly and a good bit of motion of you...

Page 24: ...ll start after the arc is terminated It will flow for the length of time selected for Post Flow 11 If using Live Lift terminate the arc with a quick snapping motion of your wrist so the torch tungsten is rotated away and up until the ending with the torch parallel to the weld surface This will break the arc off cleanly If done too slowly the arc will stretch out and termi nate poorly leaving poros...

Page 25: ...ARALLEL TO WHEEL FACE OR AN UNSTABLE ARC WILL RESULT Use a point for low amp use to help control arc Create a slight truncation on the tip for higher amp use for best arc stability Grind the tip so that it is 2 5 3 times longer than the tungsten is wide Diameter DO NOT BALL TUNGSTEN WHILE USING AC ERRATIC ARC WILL RESULT MAKE SURE GRINDING MARKS RUN PARALLEL TO TIP CONCENTRIC MARKS WILL CAUSE AN E...

Page 26: ... 1 Steel work clamp and cable 10 ft 1 PowerARC 210STL DC Stick DC TIG Inverter welder 1 Manual may be downloaded from website for free 1 240V 120V Adapter optional in some markets NOTE Kit contents appearance size and quantity are subject to change without notice General Setup and Operation Section 2 ...

Page 27: ...t Holder 1 7 Ceramic Cup 5 6 or 7 1 8 Tungsten customer supplied 0 9 Torch Cable 12 5 ft 1 10 Torch Handle 1 11 Torch Switch Removeable 1 12 Torch Switch Connector 1 13 9mm 1 8 quick connect coupling male Gas IN 1 14 Power Connector DINSE 25 1 15 Protective Denim or Braided Nylon Cover 1 1 2 3 4 5 6 7 8 9 9 10 11 15 14 12 EXPANDED VIEW OF TIG TORCH Actual appearance may vary slightly from what is ...

Page 28: ...eld Discolored weld color Too much spatter Additional TIG symptom Tungsten is discolored Stick Too long of arc length Too high of amps TIG Same as above Low flow rate of shielding gas Too short of post flow period Wrong TIG cup size Draft Weld quality is poor unstable arc Weld is dirty oxidized Clean paint rust from weld Make sure work clamp has good contact Too low of amps Too large of tungsten I...

Page 29: ...29 7 PIN CONNECTOR FOR FOOT PEDAL 10kΩ For NOVA Bridge to 7 Bridge to 6 To Pedal or Torch Switch To Pedal or Torch Switch The welder will accept 10k to 22k Ohm potentiometers Trouble Shooting Section 3 ...

Page 30: ...30 NOTES ...